Top Banner
GE Power Powering the World Responsibly ge.com Powering the World STEAM POWER SYSTEMS PRODUCT CATALOG
48

GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Oct 06, 2020

Download

Documents

dariahiddleston
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Page 1: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

GE Power

Pow

erin

g th

e W

orld

Res

pons

ibly

ge.com

Poweringthe WorldSTEAM POWER SYSTEMS PRODUCT CATALOG

Page 2: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Delivering highly efficient and cleaner power generationThe availability and affordability of coal makes it a critical fuel in a world that is

striving to meet the energy needs of tomorrow. Coal and oil fired power plants are

well positioned to deliver additional capacity to growing regions of the world as long

as we use our best technology to lessen the related environmental impact. If anyone

is up for the challenge, we are.

At GE’s Steam Power Systems we use our unrivalled expertise every day to help

customers get tailored systems that stand the test of time, while continually driving

improved efficiency and performance benchmarks.

We offer customers exceptional flexibility. From a single component to a full power

plant — our broad range of products covers a large scope of applications and a wide

range of fuels including coal, lignite, anthracite and petcoke. We put over 100 years

of steam power expertise to work, generating power that is reliable, efficient, easy to

integrate and operate.

Our customers can count on us to help them deliver as much energy as possible,

to the greatest number of people, in the most efficient way. Our relationship goes

beyond the technology or our team of experts; it’s a partnership based on a shared

commitment to make sustainable power possible for people around the world, and

right around the corner.

© 2015, General Electric Company and/or its affiliates. GE Proprietary Information. All Rights Reserved. No part of this document may be reproduced, transmitted, stored in a retrieval system nor translated into any human or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written permission of the General Electric Company or its concerned affiliate.

Page 3: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Industry Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Key Differentiators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technology Leadership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

The Plant Integrator Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Standardized/Pre-Engineered Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Flexible Offerings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Power Plant Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Steam Turbines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Air Quality Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

CO2 Capture Solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

CONTENTS

Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice.

Page 4: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

40%

35%

15%

5%Europe (ind. Turkey)

North America

Latin America

Oceania

Russia and CIS

Middle East and Africa

Asia (exd. China and India)

India

China

Bituminous

Sub-bituminous

Lignite

NOTE: Reserve �gures in trillions tonnes

NAM 270

LAM 18

Africa 55

Oceania 85

India 62

China 126

Russia 173

RoA 12

Europe 48

An Essential Role in the Global Power MixCoal power is the most mature and the most common power generation technology in the world.

With 2,550 GW of installed capacity providing 41 percent of the global electricity supply, coal serves

as the reliable, cost-effective and durable baseload power source to utility scale networks.

Coal resources are broadly distributed around the globe and are often locally available. At current

consumption rates coal reserves should last for centuries. The use of coal for power generation can

also offer energy security by reducing dependence on more restricted fuel supplies.

2 3

STEAM POWER SYSTEMS PRODUCT CATALOG I Global Overview

COAL POWERIndustry Overview

2,550 400 1,440 1,855

10,000 2,550 5,050 6,050

InstalledBase (GW)

ElectricityGenerated (TWh)

6,245 GW

23,650 TWh

Coal Nuclear Gas Other

41% 7% 23%

42% 11% 21%

30% Total Worldwide

26%

Coal Power Market for the Next 10 Years

25%of all future power capacity additions will be coal- or oil-fired steam power plants

95%of the global demand will come from fast-growing economies in India, China, Asia, the Middle East and Africa

Coal ReservesCapacity Additions

Market Drivers• Affordable energy• Available and reliable supply• Fuel flexibility• Emissions regulations

Reducing Emissions to Mitigate Global Environmental ConcernsGE’s Steam Power Systems is an industry leader in cleaner power generation from coal and oil. Stringent regulations to limit emissions have been deployed, revised and reinforced for decades. The U.S. and parts of Europe have strict emission regulations in place, while China has implemented, and India is developing, environmental control strategies to cope with booming development of their coal-based industries.

With more than 80 years of experience providing Air Quality Control Systems (AQCS), GE has the expertise, technology and extended product portfolio to reduce gaseous emissions from coal (or oil) combustion and meet today’s most stringent emission requirements.

To reduce CO2 emissions, GE is contributing on two major fronts. First, GE has designed, installed and commissioned many of the highest efficiency coal and oil plants in the world, which not only optimize the operating costs (reduced fuel consumption per MW produced) but also reduce the CO2 emitted per MW produced. Second, GE has developed and industrially tested CO2 Capture solutions which are fully ready for large-scale deployment.

Highly efficient power generation from coal and oil

The demand for new coal power plants in the next 10 years will come predominantly from the prospering emerging regions of the world.

* Source Alstom, Status end of 2014

Widely dispersed and abundant coal resources provide a highly secure supply for coal power generation.

Powering the World

Page 5: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

4 5

STEAM POWER SYSTEMS PRODUCT CATALOG I Technology Leadership

GE has the expertise and resources to meet specific customer needs with a portfolio of products covering

commonly used fuels for power generation. With fossil fuel power plants likely to continue as the

main providers of global power generation, the efficient and reliable conversion of fuel into electricity will

remain critically important.

Efficiency IncreaseAt GE, we are always working to lower fuel consumption and emissions by increasing power plant efficiency. Our advanced power plants use ultra-supercritical technology. Other improvements in power plant efficiency include:

• Double-reheat technology

• Cold end advancement

• Flue gas heat recovery systems

To optimize the thermodynamic cycle, we have enhanced the design of each component to improve overall efficiency of the plant.

Future developments from GE include advanced USC (>700°C) technology and pre-drying technology for high-moisture lignite.

Proven Fuel ExpertiseOur cleaner combustion technologies:

• Cover a large spectrum of fuels, from bituminous to lignite coals to oil and gas, heavy residues, biomass, and others

• Have experience with the most difficult fuels (e.g. Oil Shale, VRO, high-moisture, etc.)

• Are designed to remain insensitive to variations in fuel composition

Operational Flexibility and ReliabilityOur products deliver high operational flexibility to accommodate the growing requirements of power generation from renewables.

Experience derived from a huge installed fleet helps us to continually improve our products and increase their operational reliability.

Our products and designs deliver high availability and easy maintenance for:

• Shorter planned outages

• Reduced life-cycle costs in the power station

Emissions ReductionTo lower the impact of power generation to the environment, our AQCS products enable power plants to conform to today’s strict environmental standards for air emission levels.

In addition, we have developed a portfolio of technologies for CO2 capture that includes pre- and post-combustion processes suitable for new builds as well as the retrofit of existing plants.

GE’s Advanced USC Developments

Today

Cha

nge

in o

vera

ll p

lant

net

e�

cien

cy (r

elat

ive)

+4.0%

+6.0%+6.7%

+8.7%

+11.3%

170 bar540°C540°C

Sub-critical

Baseline240 bar565°C565°C

Supercritical

260 bar600°C600°C

275 bar600°C620°C

300 bar600°C

620/620°C

350 bar700°C720°C

Ultra-Supercritical Double reheat 700+°C

FIRSTWorld’sUSC50 YEARS OF OPERATION

At Eddystone PlantPhiladelphia, PA USA

202,000MWeor 313 boilers installedusing USC technology

36%of our steam turbinesin the last 10 years

are USC

Delivering High Efficiency Coal Power to Our Customers Globally• 912 MW USC, Germany: greater than

46 percent net efficiency

• 911 MW USC with CHP, Germany: flexible

energy production (electricity + district heating

+ railway power) resulting in fuel utilization

up to 70 percent efficiency

• 1,080 MW USC, Malaysia: the first USC 1,000

MW-class plants in Southeast Asia. Efficiency

over 43 percent (at local cooling temperatures)

Powering the World

Key Differentiators

TECHNOLOGY LEADERSHIP

912 MW USC, Germany

Page 6: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Our Plant Integrator approach is based on our ability to combine GE’s components and auxiliary equipment into fully enhanced and integrated systems. The return of experience from manufacturing, construction, commissioning and operation results in a systematic continuous improvement of GE’s components and standardized/pre-engineered solutions. This leads to improved performance, as well as cost and delivery time reduction of our offering to our key markets and helps our customers achieve and exceed their objectives.

Unique Integration Capabilities• Broad in-house product portfolio – all major plant components jointly developed to work as one unit

• Demonstrated high efficiency plants meeting local requirements

• Flexible offerings – from single OEM components up to full turnkey power plants

• Global flue gas chain management from boiler to stack – controlled emission footprint

Extensive Execution Experience• 100 years of experience – in building steam power plants, making GE a global leader

>100 GW installed integrated power >200 integrated projects executed globally

• Attuned to the local codes/standards

Continuous Improvement – Via Focus and Extensive Return of Experience

6 7

STEAM POWER SYSTEMS PRODUCT CATALOG I Plant Integrator Approach

Key Market Segments (local customer requirements)

Standardized/Pre-Engineered Solutions (focused product development)

Integrated Execution (overall performance

responsibility)

Flexible O�erings (improved components and

integrated solutions)

Integration(added value) Sustainable customer value and

excellence in project execution

Powering the World

Key Differentiators

PLANT INTEGRATOR* APPROACH

Page 7: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

8 9

STEAM POWER SYSTEMS PRODUCT CATALOG I Standardized/Pre-Engineered Solutions

GE has a systematic approach to developing standardized and pre-engineered components and power plant designs, while keeping sufficient flexibility to meet our customers’ needs. This approach enables us to improve the manufacturing, assembly, construction, commissioning, operation and maintenance of the power plant, which results in improved reliability and availability of our offerings.

Integrated Steam Platforms (ISP)For each major segment of the market, GE has created a pre-engineered plant approach which delivers solutions matching the specific needs coupled with competitive cycle times during offering and execution phases. These Integrated Steam Platforms (ISP) make extensive use of standardization and design-to-cost, while still maintaining sufficient flexibility to meet individual project requirements. The benefits of this approach to our clients are multifold:• Built-in flexibility: to address most of the site and project specific conditions (fuels, codes and standards, cooling

media, emission limits)• Improved quality: Re-use of proven solutions and design principles combined with continuous improvement,

systematic return-of-experience, and lessons learned from tendering, engineering and execution• Improved health and safety: Safer to construct and safer to operate• Reduced delivery times: Quicker response to customer requests during the tender phase, and

reduced construction and commissioning time• Operation and maintenance: Faster to maintain, leading to improved availability• Emissions Regulations: Each ISP is capable of meeting today’s most stringent local, regional or global

emissions requirements

1 State-of-the-art steam technology today; 2 Steam parameters at boiler outlet, typical values; 3 Efficiency values based on LHV basis and typical regional vacuum pressure.Values in table indicate pre-engineered solutions to meet local requirements, adaptions foreseen on project basis

GE’s Integrated Steam Platforms (ISP) for today’s competitive environment … and a sustainable future

Generator• Standardized and reliable product families related to cooling technologies• Common technologies, manufacturing processes, tools and materials

Air Quality Control Systems (AQCS)• Standardized components, processes and tools• Parametric designs for �exibility to meet environmental requirements

Steam Turbines• Global modular approach of the steam turbine frames with standardized interfaces• Flexibility in the steam path design

Boiler Island• Standardized steel structure designs, components and piping sizes• Standardized heating surface components across power output range

Global Product Standardization Initiatives

Turbine Island• Globalized design by freezing positions and dimensions with speci�c variants• Increased design commonality

Integrated Steam Platform• Designed for local requirements• Can consist of pre-engineered solutions of the following o�erings

Turnkey Power BlockTurbineIsland

i.PP(Integrated Power

Package)

Stand-Alone

Components

ISP Europe 900

Asia 660

Asia 1100

India 660

India 800

Fuel TypeDomestic/Imported Bituminous and Sub-Bituminous Coal

Domestic/Imported Bituminous and Sub-Bituminous Coal

Domestic/Imported Bituminous and Sub-Bituminous Coal

Domestic/Imported Bituminous and Sub-Bituminous Coal

Domestic/Imported Bituminous and Sub-Bituminous Coal

Gross Power Output (MW) 900 660 1100 660 800

Water/Steam Cycle1 Ultrasupercritical Ultrasupercritical Ultrasupercritical Ultrasupercritical Ultrasupercritical

Live Steam Pressure (bar)2 ≤ 294 ≤ 294 ≤ 294 ≤ 294 ≤ 294

Live Steam Temperature (°C)2 ≤ 605 ≤ 605 ≤ 605 ≤ 605 ≤ 605

Hot Reheat Temperature (°C)3 ≤ 623 ≤ 623 ≤ 623 ≤ 623 ≤ 623

Net Plant Efficiency (%)3 ≤ 46.3 ≤ 43.5 ≤ 43.5 ≤ 43.0 ≤ 43.0

Boiler Type (typical) Tower Two-Pass Two-Pass Two-Pass Two-Pass

Cooling Technology direct / cooling tower direct / cooling tower direct / cooling tower direct / cooling tower direct / cooling tower

Vacuum Pressure (mbar) 20 - 30 60 - 80 60 - 80 70 - 100 70 - 100

Number of preheaters 9 8 8 8 8

Feedwater pump drive (typical) motor motor / turbine turbine turbine turbine

Powering the World

Key Differentiators

STANDARDIZED/PRE-ENGINEERED SOLUTIONS

Page 8: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

FLEXIBLE OFFERINGSFreedom to Fulfill Individual Customer Requirements

10 11

STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings

The OEM with the full in-house product capability from conceptualization to final design

Powering the World

GE applies the concept of flexible offerings across our portfolio, allowing our customers to select from a portfolio of products and systems that meet their specific requirements, while maintaining the key benefits of standardization and pre-engineering processes. In addition, GE’s Plant Integrator* approach can deliver added value across the full range of offerings.

Integrated Offerings - Flexible ScopeFrom the basic engineering of our core components in our Integrated Power Package (i.PP) to the full turnkey plant, GE can address all customer needs.

Integrated Offerings - Flexible OutputFrom individual components to the full turnkey plant, GE provides integrated offerings for power output from 100 MW to 1,200 MW across a wide range of fuels for steam power generation.

COMPONENTSINTEGRATED

POWERPACKAGE

FULL TURNKEYPLANTS

POWERBLOCK

TURBINEISLAND

PLANT INTEGRATOR*

Boiler Types Power Output Range (MW)

300–1,200 MW

100–660 MW

400–800 MW

Pulverized Coal (PC)

Circulating Fluidized Bed (CFB)

Heavy Fuel Oil (HFO)

Page 9: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Whether you are a power plant owner or an EPC contractor, sourcing the main power generation

equipment for your new build is the most important decision you will make. GE’s Integrated Power

Package (i.PP) supplies our customers with our world-class boilers, and turbines, all of which have

been conceptualized to operate as one unit, allowing us to provide excellent performance and power

output. With our flexible offerings concept, customers can add additional GE equipment, providing them

with enhanced quality and performance.

12 13

STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings

Saudi Arabia5 x 620 MW Integrated Power Package (i.PP)

Product620 MW supercritical heavy fuel oil (HFO) and gas-fired (dual fuel) power plantScopeIntegrated Power Package (i.PP) including AQCS— Boiler, steam turbine, generator— Electrostatic precipitators and flue gas desulfurization system— Basic engineering of the power block— Advisory and site services— CommissioningBenefits• Overall performance and emission guarantees (power output,

heat rate, emissions)• Steam extracton for desalination

Saudi Arabia’s first supercritical power plant to run on HFO

Basic i.PP Offering

+Integration

(basic engineering and functional specifications for power block)

+Overall Performance Guarantee

(power output, heat rate, emissions)

Integrated Power Packages – ideal solution for competitive EPC contractors

Contributes to 90 percent of the plant performance, using just the core OEM components

Boiler (core parts): (all pressure parts, the firing system, mills)

Steam Turbine,Generator,

AQCS (optional)

Powering the World

Flexible Offerings

INTEGRATED POWER PACKAGE (i.PP)

Page 10: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

The turbine island is one of the most critical parts of the power plant, and of prime importance is

the integration of key parameters and interfaces among the auxiliary components and steam water

cycle. With proven equipment and systems, the plant is able to consistently deliver the desired output

throughout the product’s life cycle. GE’s flexible offering allows for excellent layout of the turbine hall,

providing significant savings in construction and labor costs.

14 15

STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings

India7 x 660 MW SC Turbine Islands

Product660 MW Turbine IslandScope• Steam turbine and auxiliary equipment• Generator and auxiliary equipment• Condensate system• Feed water system• Control, protection and instrumentation• Construction and commissioningBenefitsIntegrated and enhanced systems meeting Indian requirements

Steam Turbine, Generator,Heat Exchangers

Scope of Offering

+Balance of Turbine Island

(feedwater pumps or turbines, piping, valves, control systems)

+Integration, Construction and

Commissioning, O&M

+Overall Performance Guarantee

(power output, heat rate)

Providing critical OEM steam turbine, generator and enhanced water steam cycle interfaces

Powering the World

Flexible Offerings

TURBINE ISLAND

Page 11: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

One of the most complicated and critical challenges of integration in a plant is the power block.

The power block consists of the power plant’s critical equipment including boiler, steam turbine,

generator, air quality control systems and associated auxiliary systems. Integration is key to plant

performance over its lifetime and provides a quicker and lower risk return on investment. However,

successful integration requires a global footprint and world-class EPC capabilities. GE’s competitive

power block offering is based on our extensive global experience integrating key components with varied

scope of supply and our proven solutions.

16 17

STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings

Poland2 x 930 MW USC Power Block

Product930 MW coal-fired, ultra-supercritical power plantScope• Boiler island including FGD and ESP• Turbine island including turbine hall equipment• Balance of Power Block (BoPB)• Construction and commissioning supportBenefits• High efficiency (approximately 45.5 percent)• Meets stringent European emissions regulation:

sulfur dioxide (SOx), nitrogen oxides (NOx) and particulate matter

Poland’s largest coal-fired power plant

Full Boiler Island, Full Turbine Island AQCS Equipment (optional)

Scope of Offering

+Balance of Power Block

(service systems: cooling water, compressed air, HVAC, fire fighting, electrical building and transformers)

+Integration, Construction and

Commissioning, O&M

+Germany1 x 912 MW USC Power Block

Product912 MW coal-fired, ultra-supercritical power plantScopeFull turnkey power blockBenefits• Overall net plant efficiency of more than 46 percent

(greater than 58 percent with district heating)• Meets stringent European emissions regulation:

— CO2 < 740 g/kWh

— CO and NOx < 100 mg/Nm3

One of the highest efficiency steam power plants in the world

Overall Performance Guarantee(power output, heat rate, emissions)

Design and integration of all critical equipment and systems at the power plant level

Powering the World

Flexible Offerings

POWER BLOCK

Page 12: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Today’s plant owners and power operators know that it takes more than selecting a set of high efficiency

components to achieve advanced economic and technical goals. In order to maximize long-term returns on

investment, it takes a company like GE, with extensive experience and world-class EPC capabilities – such

as project management, logistics, and construction management. GE’s range of capabilities in design and

integration of steam power plant solutions gives us a unique perspective that allows us to analyze the

entire plant over its full life cycle as an integrated system.

18 19

STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings

Malaysia2 x 1,080 MW USC Coal Plant

Product1,080 MW coal-fired, ultra-supercritical power plantScopeTurnkey EPC contract with consortium partnerBenefits• Additional capacity to meet strong demand in

fast-growing economy• Continued relationship between customer and GE following successful

supply of three previous units

Malaysia’s first ultra-supercritical coal-fired unitsFull Power Block

Scope of Offering

+Balance of Plant

(water intake, polishing unit, stack, cooling tower, fuel systems, coal/ash handling, switchyard)

+Integration, Construction and

Commissioning, O&M

+Poland1 x 858 MW USC Lignite Plant

Product858 MW coal-fired, ultra-supercritical power plantScopeFull turnkey steam power plantBenefits• Higher efficiency (close to 42 percent)• Lower emissions of sulfur dioxide (SOx) and nitrogen oxides (NOx)

Poland’s largest and most efficient lignite-fired plant

Overall Performance Guarantee(power output, heat rate, emissions)

Providing the full GE advantage with enhanced economics, shorter lead times, extended performance and reduced O&M costs over the life cycle of the plant

Powering the World

Flexible Offerings

FULL TURNKEY PLANT

Page 13: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

21

BOILERSPortfolio and Overview

20

STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers

Two-Pass Tower CFB

CO

AL

Lignite B

Lignite A

Subbit. C

Subbit. B

Subbit. A

Bit. High Vol. C

Bit. High Vol. B

Bit. High Vol. A

Bit. Med. Vol.

Bit. Low Vol.

Semi-Anthracite

Anthracite

Meta-Anthracite

OIL

Heavy Fuel Oil

Vacuum Residual Oil

Crude Oil

GA

S

Natural Gas

Coke Oven Gas

Blast Furnace Gas

OP

PTY

. FU

EL

Biomass

Oil Shale

Petcoke

Waste Coal

Unparalleled Fuel ExpertiseOur knowledge of fuels

and combustion, a core GE

competence, is derived from

our extensive laboratory and

field experience. With these

technologies, our customers

can burn a wide spectrum of

fuels, from high-rank coals

to low-rank coal wastes, and

from oil and natural gas to

opportunity fuels such as

petroleum coke, biomass

and oil shale. With our leading

technologies and a globally

proven product portfolio,

GE provides excellent fuel

firing flexibility that can

lower the cost of electricity

for our customers.

* SHO temperature/RH temperature/SHO pressure

GE’s boiler technology has a heritage of more than 100 years, and our installed base of utility boilers

makes up about 30 percent of all boilers installed or under construction worldwide. As an industry

leading supplier of efficient, flexible and reliable boilers for power generation, GE offers both two-pass

and tower designs that can burn a wide range of hard coals, lignite, and oil/gas, and offers circulating

fluidized bed boilers for both conventional and difficult-to-burn fuels.

Full Boiler Product Portfolio

Two-Pass Boiler Tower Boiler CFB Boiler

TYP

ICA

L FU

ELS

• Bituminous, sub-bituminous• Lignite A• Oil and gas

• Bituminous, sub-bituminous• Lignite A and B

• Anthracite through lignite A and B

• Opportunity fuels: petroleum coke, biomass, waste coal, oil shale, etc.

CA

PAC

ITY

• Up to 1,350 MWe • Up to 605°C/623°C/300 bar*

• Up to 1,350 MWe • Up to 605°C/623°C/300 bar*

• Up to 660 MWe for lignite, higher for hard coal

• Up to 605°C/623°C/285 bar*

FEA

TUR

ES/

AD

VAN

TAG

ES

• Most commonly used technology• Specialized for oil and gas firing• Faster construction with

simultaneous construction on both passes

• Simple roof penetration

• Especially designed to burn high moisture lignite

• Simple and reliable design• Faster startup• Smaller footprint

• Suited to low-grade fuels • Can simultaneously burn

different fuels• No need for SCR and WFGD• Higher reliability with

modular design

Flexible Scope of SupplyGE has a full range of boiler offerings, from boiler to complete boiler island configurations, depending

on our customers’ specific project needs.

Efficient, flexible, reliablesteam generation

Powering the World

Co-firing in limited amountsTower boiler is capable of oil and gas firing if requested by the customer.

Page 14: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers

2322

Tangential Firing SystemGE introduced the tangential firing system in 1927. Fuel and air are injected through windboxes from the

corners of the furnace, aimed tangent to an imaginary circle in the center of the furnace. This creates a

single rotating flame envelope (vortex) that produces a uniform and consistent heat profile across the

furnace walls over the operating load range. Due to aerodynamics, the fuel and air are mixed throughout

the furnace, resulting in high efficiency combustion. Tangential firing also provides the following

advantages for GE’s two-pass and tower boiler designs:

Industry Leader in Supercritical and High EfficiencyGE led the industry in developing supercritical steam generation technology, and is an industry leader in today’s high efficiency ultra-supercritical technology. Our expertise in thermal, hydraulic, and material sciences has led to boiler designs that offer tremendous improvements in steam parameters. Advanced tangential firing systems can lower exhaust gas emissions, providing an additional benefit as countries seek to lower emissions.

High EfficiencyGE’s ultra-supercritical boilers contribute to cycle efficiencies of 42 to 45 percent on an HHV basis (44 to 47 percent LHV basis), significantly reducing both fuel and emission control costs for our customers.

Extensive Experience and ReferenceTo date, GE has directly supplied more than 116,000 MW of supercritical/ultra supercritical boilers worldwide, and has licensed and trained other companies to install an additional 140,000 MW.

Continuous DevelopmentGE continues to invest significantly in research and development dedicated to improving our high efficiency power generation equipment.

• Ultra-supercritical circulating fluidized bed (USC CFB): With our world-class experience in ultra-supercritical pulverized coal boilers and expertise in the design of CFB firing, GE has developed highly efficient ultra-supercritical CFB technology, which provides reliable and fuel-flexible power generation with a lower CO2 footprint.

• Double reheat (DRH): GE has supplied double reheat boilers for more than 50 years, and today we offer USC double reheat configurations for both tower and two-pass boiler designs.

• Advanced ultra-supercritical (A-USC): GE is in collaboration with various groups in Europe (700°C) and the U.S. (760°C) for A-USC steam cycle development.

Efficiency Improvement with Increasing Steam Conditions

Powering the World

BOILERSPortfolio and Overview

Steam conditions in bar/ºC/ºC (psi/ºF/ºF)

167/540/540(2,400/1,000/1,000)

240/540/565(3,500/1,000/1,050)

275/580/600(4,000/1,075/1,100)

275/600/620(4,000/1,100/1,150)

375/700/720(5,400/1,300/1,325)

375/730/760(5,400/1,330/1,400)

R&D ongoing USA USC Materials Consortium & ECAD 700 Project (Ni-base)

1960 1980 2000 2020

SUBCRITICALSUPERCRITICAL

ULTRA-SUPERCRITICAL (USC)

ADVANCED USC

• Low primary NOx emissions for decreased SCR catalyst

volume, reagent use, and maintenance requirements

• Efficient use of furnace volume, resulting in reduced slagging

tendency and soot-blowing frequency

• Excellent flame stability for increased unit turndown and

a wider latitude for fuel property variation

• Tilting capability resulting in no attemperation for reheat

temperature controls

Page 15: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

2524

STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers

Ultra-supercritical CFB660 MWe for lignite B, higher for hard coal

• Ultra-supercritical 285 bar, 605°C/623°C (MS/RH)

• More than three points increased net plant

efficiency relative to subcritical

• Six percent reduction of CO2 footprint

• Inherent low NOx emission with our air staging

• Low SO2 emission without backend treatment

• Designed for reliability:

— Well-tested material for pressure parts with

many years of onsite experience

— Multiple fuel feeders and ash extraction ports

— Standardized modules that allow changing

outputs, fuels and steam temperatures

With no additional flue gas treatment as SCR and WFGD

Emissionsmg/Nm3

@ 6% O2 dg ppm lb/mm Btu

NOx 150 75 0.12

SOx 200 70 0.16

Lignite B India Malaysia Turkey Germany Poland Hungary Indonesia

Moisture (%) 58 50 46 60 46 48 55

Ash (%) 6 8 13 5 11 20 4

VM daf basis (%) 54 51 51 54 56 65 59

Sulfur (%) 0.5 0.4 2.0 0.2 0.4 1.5 0.1

HHV af basis (mBtu/lb) 4.2 4.7 5.6 4.3 5.9 4.4 4.8

LHV ar (Mcal/kg) 1.8 2.1 2.3 1.8 2.5 1.6 2.1

Typical lignite analyses used for sizing the 660 MW CFB-firing system

Typical emissions:

Powering the World

Cleaner, efficient, flexible, reliable, steam generation for all type of fuels

BOILERSPortfolio and Overview

Page 16: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

27

Coal-fired Two Pass Oil and Gas–fired Two Pass

Fuel • Bituminous

• Sub-bituminous

• Lignite A

• Oil (Heavy Fuel Oil, No. 2 Oil, No. 6 Oil, Crude Oil etc.)

• Gas (Natural Gas, Coke Oven Gas, Blast Furnace Gas etc.)

Steam Cycle • Ultra-supercritical

• Supercritical

• Subcritical

• Supercritical

• Subcritical

Size (MWe) • Subcritical ≤ 800

• USC/SC ≤ 1,350

• Subcritical ≤ 800

• SC ≤ 1,000

Superheater Outlet Steam Pressure (bar) • ≤ 300 • ≤ 250

Superheater Steam Temperature (°C) • ≤ 605 • ≤ 565

Reheater Steam Temperature (°C) • ≤ 623 • ≤ 565

Design Features • Tangential firing system

• Fuel and air staging

• Tilting burners

• Vertical and spiral wall designs

• Tangential firing system

• Fuel and air staging

• Tilting burners

• Spiral wall designs

TWO-PASS BOILERSFurnace and Convective Passes, Tilting Tangential Firing System, Experience Firing Fuels from All Over the Globe

GE’s two-pass boiler is the workhorse of the power industry, generating steam for today’s large-scale

global power projects (up to 1,350 MWe) at pressures and temperatures that can reach the service limits

of contemporary materials. Radiant pendant surfaces are located above the furnace, and convective

surfaces are arranged horizontally in the second pass. The two-pass configuration results in an

efficient furnace height and a lower cost of construction. Our patented tilting tangential firing system

accommodates the large spectrum of fuels found across the globe (multiple grades of coal, oil, gas, heavy

residues, biomass and other opportunity fuels), and is a leader in primary emissions control.

26

Coal-fired Two Pass Oil and Gas-fired Two Pass

STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers

Flexible and Reliable• High cycle efficiencies at ultra-supercritical

conditions reaching 44 to 47 percent on an LHV basis (42 to 45 percent HHV basis), meaning less fuel consumption and cleaner operation

• Low primary NOx emissions using advanced tangential firing systems and effective overfire air arrangements, resulting in less SCR catalyst material and less reagent consumption

• Outstanding operational flexibility for temperature control, grid code requirements, sliding pressure capability, and load cycling

• Reduced construction time and cost using advanced construction techniques and standard component design and fabrication

Powering the World

Page 17: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Powering the World

GE originally introduced the tower boiler design in the mid-20th century to utilize high moisture lignite in Europe. Since then, thanks to its advantages – and positive feedback from customers – the tower boiler has become the predominant design for coal-fired power generation in Europe, according to the EN Codes & Standards. With standardization and modularization, tower boiler equipment can be sourced and constructed cost-effectively around the globe while meeting high quality standards.

Flexible and Reliable• High cycle efficiencies at ultra-supercritical conditions reaching 44 to 47 percent on an LHV basis

(42 to 45 percent HHV basis), meaning less fuel consumption and reduced emissions

• High steam parameters with successful utilization of T24 material

• Low primary NOx emissions using advanced tangential firing systems and effective overfire air arrangements, resulting in less SCR catalyst material and less reagent consumption

• Outstanding operational flexibility to support a stable grid

• Reliable plant operation enhanced by fully drainable heating surfaces, resulting in faster startup periods and reduced stresses in pressure part

Expertise in High Moisture Lignite Firing

TOWER BOILERSSimple and Reliable Design, Expertise for High Moisture Lignite Firing

29

Hard Coal Fired Tower Lignite Fired Tower

Fuel • Bituminous

• Sub-bituminous

• Lignite A

• Lignite B

Steam Cycle • Ultra Supercritical

• Supercritical

• Subcritical

• Ultra-supercritical

• Supercritical

• Subcritical

Size (MWe) • Subcritical ≤ 800

• USC/SC ≤ 1350

• Subcritical ≤ 800

• USC/SC ≤ 1,100

Superheater Outlet Steam Pressure (bar)

• ≤ 300 • ≤ 300

Superheater Steam Temperature (°C) • ≤ 605 • ≤ 605

Reheater Steam Temperature (°C) • ≤ 623 • ≤ 613

Design Features • Tangential firing system

• Fuel and air staging

• Tilting burners

• Spiral wall designs

• Tangential firing system

• Fuel and air staging

• Spiral wall designs

• Expert firing system for lignites

Hard Coal Fired Tower Lignite Fired Tower

28

STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers

Furnace gas resuction ducts

Beater wheel mills

Mills arranged around furnace Large furnace

• Specialized firing system to burn all types of

lignite with over 80 years of experience

• Integrated with advanced beater wheel mill

providing efficient operation and maintenance

Page 18: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

During the past two decades, circulating fluidized bed (CFB) technology has demonstrated its ability to efficiently utilize a wide variety of fuels – including fuels with high ash, high moisture, high sulfur, low volatiles, and low heating value that are unsuitable for other firing systems – while meeting stringent stack emission limits. This unique combination of fuel flexibility and low emissions has led to the development and growth of CFB technology in power generation.

• Efficient Combustion

A wide range of fuels can be burned efficiently, including low-grade and difficult-to-burn fuels such

as anthracite, lignite, petroleum coke, oil shale, discarded coal and biomass.

• Fuel Flexibility

Several different fuels can be fired in the same boiler within a wide range of mixing rates.

• Low inherent NOx emissions at 50-200 mg/Nm3

— Relatively low and uniform furnace temperatures of approximately 850°C to 900°C

— Air staging in the lower furnace through the introduction of primary air and secondary

air at appropriate levels

— Uniformly distributed fuel and air due to intense mixing inside the bed of solids in the furnace

— Isothermal conditions in the circulating solid loop due to the positive impact of

highly efficient cyclones

— Selective non-catalytic reduction (SNCR) systems can be added, leading to even lower

NOx emissions

• Low SO2 emissions with 95 to 98 percent sulfur removal

— Injection of prepared and dried limestone in the furnace

— Potentially inherent capture by the fuel-bound calcium

— Dry scrubber NID* achieving 98 percent sulfur removal while reducing limestone consumption

— Just-In-Time (JIT*) system for limestone drying and crushing available for direct limestone feeding

30

STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers

CFB BOILERSCombination of Fuel Flexibility and Low Emissions

Dual-Grate Arrangement Design for specific requirements

Three-Bay ArrangementMost common CFB design

Advanced Supercritical CFBLarge-sized CFB firing system

Fuel Entire range of fuels, including opportunity fuels such as petroleum coke, biomass, waste coal, oil shale, etc.

Steam Cycle • Subcritical • Subcritical • Ultra Supercritical

• Supercritical

Size (MWe) • 350 • 100 – 350 • 660 for lignite B

• Higher for hard coal

Superheater Outlet Steam Pressure (bar)

• ≤ 175 • ≤ 175 • ≤ 285

Superheater Steam Temperature (°C)

• ≤ 565 • ≤ 565 • ≤ 605

Reheater Steam Temperature (°C)

• ≤ 565 • ≤ 565 • ≤ 623

Design Features • Four cyclones • Double grates• External beds

• Up to three cyclones in line • Single grate• In-furnace panels• Steam cooled cyclones

• Modular concept• Standardized modules • Up to 8 cyclones• Steam cooled cyclones• Double fluidizing grates• External beds• In-furnace box columns • In-furnace U-shaped panels

• CFB/NID integrated technology • SNCR in-house injection grid • JIT limestone feed system

Powering the World

Dual-Grate Arrangement Three-Bay Arrangement Advanced Supercritical CFB

31

Page 19: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

32 33

For nearly 100 years – ever since pulverized coal combustion was adapted for power generation – GE

has been a leader in coal mill technology for the power industry. That leadership continues today

with the world’s largest fleet of installed power milling equipment. Licenses for our milling technology

can be found in all coal-powered regions of the world.

Pulverizing solid fuel to powder enables its drying and transport for combustion in large furnace sizes.

Fine grinding increases the fuel exposed surface area while simultaneously drying and controlling

its distribution. These are integral steps to efficient, low emissions combustion which are optimized

together with boiler thermal performance.

We design and continuously develop a complete range of milling technology that includes vertical

spindle bowl mills and beater wheel mills, with classifier options to match our customers’ efficiency

and fuel flexibility demands. Our mill and classifier portfolio can process all fuels commonly used for

power generation and fuel blends, while maintaining excellent combustion efficiency under low-

emission conditions with reduced power consumption and maintenance requirements.

Bowl Mills – HP Type Bowl Mills – SM Type Beater Wheel Mills – Type S, V, SV

Capacity Range (t/h)

• 18 to 170 • 12 to 170 • 44 to 170 (diam. ≤ 4.4m)

Classifier • Static or dynamic • Static, dynamic and combined • Box type (static)

Loading • Spring (hydraulic option) • Hydraulic (spring option) • Speed control for operational flexibility

Coal • Bituminous/sub-bituminous • Lignite A

• Bituminous/sub-bituminous • Lignite A • Anthracite• Petroleum coke

• Various types of lignite with moisture from 25 to 70 percent and ash content up to 35 percent

Design Features

• Interchangeable components• Removable gearbox• External spring loading• Tilt-out journals • Simple fabricated design • Adaptable arrangements• Extended life moving parts

• Interchangeable components• Removable gearbox• External spring loading• Tilt-out journals • Simple fabricated design • Adaptable arrangements• Extended life moving parts

• Optimized performance designs • Modular heavy duty design• Unique maintenance concept• Easy access to wear parts• Pre-beater design available• Insensitive to sudden load changes • Compliance with European

standards

STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers

MILLSComplete Range of Technology to Meet Low Emission, High Efficiency and Fuel Flexibility Demands

• Demonstrated reliable operation

• Wide fuel range capability, with the ability to handle all solid

fuels suitable for power generation, from anthracite to lignite B

• Enhanced operational flexibility, handling fuel blends, transient

operation, and load ramping, while supporting emissions

compliance

• Reduced capital, labor, maintenance, and operating costs:

— Simple modular design that keeps capital and construction

costs low

— Interchangeable modular components that reduce inventory

costs and repair cycle time

— Unique construction concepts that allow mill installation

without welding for reduced labor costs

Powering the World

Bowl Mills – HP type

Bowl Mills – SM type

Beater Wheel Mills – Type S, V, SV

Page 20: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines

STEAM TURBINESPortfolio and Overview

Power and PerformanceA world leader in the development and application of steam turbine technology, GE has supplied more

than 30 percent of the world’s installed steam turbine capacity, totaling more than 930 GW of power

production capability to date in operation. For more than a century, we have consolidated the best

available technology from numerous suppliers into a single platform that supports our advanced,

innovative, efficient and reliable turbine solutions.

GE’s steam turbine platform offers a broad product portfolio that accommodates a wide range of site

conditions, operational needs, advanced steam cycles, and applications. In fossil-fired steam plants,

our steam turbines offer class-leading ultra-supercritical steam parameters.

Experienced and AvailableA systematic evolutionary platform approach that incorporates best practices and technology gains

based on years of practical experience forms the backbone of GE’s coordinated product portfolio.

Our highly qualified and specialized engineering centers and factories – in key marketplaces around

the world – enable us to provide this exceptional portfolio of steam turbine products.

Advanced TechnologyIncreased Efficiency• Continuous improvements to the water steam cycle

are supported by our broad rear stage portfolio.

• Our advanced 3D blading platform helps enhance the load grade and customize the flow path for project-specific conditions and increased performance.

Evolutionary Platform Approach• The application of proven design principles to all module

types and sizes helps achieve higher reliability.

• Operational feedback is systematically applied across GE’s entire modular turbine product portfolio to enhance customer value.

34

Products

35

High Availability and Reliability• Advanced lifetime assessment procedures reduce

maintenance and increase turbine availability.

• Our long-term testing program validates material behavior to help ensure high reliability of our steam turbine components.

Enhanced Operational Flexibility• Advanced fracture mechanic methods provide reliable

lifetime assessment of the steam turbine components and increased cycling capabilities.

• An enhanced blade groove design reduces thermal stresses for increased rotor life.

GE ST-D250

GE ST-A200

GE ST-D850

GE ST-A650

GE ST-D650

100 200 300 400 500 600 700 800 900 1000 1100 1200

GE ST-D1050REHEAT Up to 300bar (4351psi)Up to 600°C (1112°F)

REHEATUp to 245bar (3553psi)Up to 585°C (1085°F)

REHEATUp to 190bar (2756psi)Up to 565°C (1049°F)

REHEATUp to 190bar (2756psi)Up to 565°C (1049°F)

NON-REHEATUp to 140bar (2031psi)Up to 565°C (1049°F)

NON-REHEATUp to 140bar (2031psi)Up to 565°C (1049°F)

Up to54.0.%ST efficiency

Up to49.0%ST efficiency

Up to47.5%ST efficiency

Up to47.5%ST efficiency

Up to40.5%ST efficiency

Up to40.5%ST efficiency

Powering the World

Page 21: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Key Technical Features

36 37

STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines

STEAM TURBINESPortfolio and Overview

Welded RotorsIntroduced in 1930, our welded rotor technology has stood the test of time with no ruptures reported in our large diameter rotors – manufactured by welding together separate smaller forgings. This beneficial design allows for:

• Appropriate forging material selection, based on temperature level at each section of the turbine

• Stress reduction during thermal transients for faster and more frequent load cycling capability

• Better access for ultra-sonic testing equipment – translating to higher reliability

Shrink Ring DesignOur shrink ring design allows for a rotationally symmetric inner casing resulting in:

• Reduced distortions while clearances are maintained during operation – providing sustained higher efficiency

• A more compact design with smaller wall thicknesses for flexible load cycling and faster startup times

Single Bearing DesignOur multi-casing turbines have a single bearing between each turbine section for:

• Avoidance of load shifting for higher reliability

• Efficient shaft alignment for reduced construction time

• Shorter overall turbine shaft length for lower building costs

LP Large Last Stage BladesOur enhanced last stage blade portfolio offers:

• Dense staggered last stage blade sizes for project-specific cold-end conditions and increased efficiency

• A robust design with stress-enhanced grooves and blade attachments for higher reliability

Advanced BladingInnovative blading technology is apparent in our:

• Modern, three-dimensional profile design that results in higher efficiency

• High pressure (HP), intermediate pressure (IP), and low pressure (LP) front stage blades that are milled from a single forging for excellent mechanical integrity and higher reliability

Blade size for 50 Hz and 60 Hz

50 Hz/60 Hz 33” (50 Hz) 33” (50 Hz) 37”/30” 41”/34” 41”/34” 45”/38” 49”/42”

Design Free-standing Snubber Free-standing Snubber and Shroud

Material Steel Titanium

Powering the World

Page 22: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

D1050, D850, D650, AND A650 STEAM TURBINESModular Steam Turbine Platform for High Efficiency

GE’s D-Series is a modular product platform for utility reheat steam turbines in the 100 to 1,200 MW

power output range. Our modular concept governs all engineering and manufacturing processes, and

results in reduced construction and commissioning times, higher reliability, and excellent efficiency.

To enhance performance, the steam path is always adapted to the specific project requirements.

The extensive LP last stage blade portfolio for 50 Hz and 60 Hz models offers rear stage sizes from

30 inches up to 49 inches. The number and size of LP turbines can be tailored to specific site conditions.

The D1050 steam turbine configuration can have up to five casings.

D1050: 400-1200 MW output

Up to 54 percent steam turbine efficiency

D850: 200-1000 MW output

Up to 49 percent steam turbine efficiency

38 39

STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines

Designed for Efficiency and Reliability• The D-Series are designed for main inlet conditions up

to 600°C (1112°F) and 300 bar (4351 psi) and reheat temperatures up to 620°C (1148°F).

• HP turbines can be equipped with a second main steam injection system by means of integrated overload valves. This method provides additional load reserve in cases of sudden steps in power demand.

• Startup valves (TAL) help ensure a safe and trip-free runback from full load to house load after load rejection.

• HP, IP, and valve units are shipped fully assembled enabling shorter installation time on site. The LP turbine is dispatched in pre-assembled lots for easier handling and reduced construction time on site.

• Skid mounted lube and control oil systems with pre-assembled pumps, filters, valves, and interconnecting piping are available for all turbine sizes.

• Sleeved rotor couplings help ensure durable shaft alignment and smoother operation.

D650: 200-700 MW output

Up to 47.5 percent steam turbine efficiency

Powering the World

Page 23: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

40 41

Technical DataD1050 D850 D650 A650

Main SteamUp to 300bar (4351psi)Up to 600°C (1112°F)

Up to 245bar (3553psi)Up to 585°C (1085°F)

Up to 190bar (2756psi)Up to 565°C (1049°F)

Up to 190bar (2756psi)Up to 565°C (1049°F)

Reheat Temperature

Up to 620°C (1148°F) Up to 585°C (1085°F) Up to 565°C (1049°F) Up to 565°C (1049°F)

Frequency 50 Hz and 60 Hz 50 Hz and 60 Hz 50 Hz and 60 Hz 50 Hz and 60 Hz

Output ≤ 1200 MW ≤ 1000 MW ≤ 700 MW ≤ 300 MW

Steam Turbine Efficiency

Up to 54% Up to 49% Up to 47.5% Up to 47.5%

Maximum Backpressure

0.35 bar (10.34 inHg)(0.7 bar (20.67 inHg) with special high back pressure rear stages)

Control ConceptSliding pressure modeHybrid mode with or without overload valve

Sliding pressure modeFixed pressure mode

STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines Powering the World

D1050, D850, D650, AND A650 STEAM TURBINESModular Steam Turbine Platform for High Efficiency

Page 24: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

D250 STEAM TURBINEPlatform with Enhanced Design Flexibility

Decades of experience have shaped GE’s D250 platform into an innovative selection of pre-engineered

sections and modules that offer flexibility. Available with downward exhaust options, the D250

platform can be integrated into any plant configuration.

With its full modular design, the D250 platform can be tailored to meet our customers’ specific

project requirements in a double casing arrangement. Turbines with a rear stage size up to 41 inches are

completely shop assembled and shipped directly to the site to reduce construction time.

The reuse of standard sections and the consequent application of an experience return process supports

continuous product design improvements and results in the high reliability of the D250 platform.

4342

STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines

Versatile and Robust Design• The D250 platform is designed for main steam inlet

conditions up to 565°C (1049°F) and 140 bar (2031 psi).

• A single or reverse flow steam path controls axial thrust and axial thermal expansion to help ensure high reliability.

• Double flow LP turbines meet project specific back pressure requirements.

• Flexible heat extractions can be arranged along the steam path to extract the steam at exactly the pressure that is needed.

D250 Platform Technical Data

Main Steam 140 bar (2031 psi), 565°C (1049°F)

Frequency 50 Hz and 60 Hz

Output ≤ 300 MW

Steam Turbine Efficiency Up to 40.5%

Maximum Backpressure0.35 bar (10.34 inHg) (0.7 bar (20.67 inHg) with special high back pressure rear stages)

Control ConceptSliding pressure modeFixed pressure mode (control stage)Hybrid mode

Powering the World

Page 25: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

44

A200 STEAM TURBINEMultiple Steam Extractions, Flexible Arrangement Concept

GE’s A200 non-reheat steam turbines provide cogeneration of power steam in an flexible and compact

design for either 50 Hz or 60 Hz application. Our fully modular concept combines HP, IP, and LP sections

to deliver high efficiency and process steam supply.

Available with a single casing, A200 steam turbines have internally and externally controlled flow

extractions to tap steam at any point along the steam path at the desired flow and pressure

conditions. Arrangement options are available with axial exhausts.

45

STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines

Compact and Flexible• The A200 turbine is designed for main steam inlet

conditions up to 565°C (1049°F) and 140 bar (2031 psi).

• For added flexibility, the A200 steam turbine is available as a single casing solution with a single flow LP section or as double casing solution with a two-flow LP section.

• Turbine cylinders are shipped fully assembled to reduce site work and construction time.

• An extensive LP blades portfolio allows a customized rear stage selection to fit all ambient conditions and achieve higher efficiency steam cycles.

• A flexible arrangement of steam extraction nozzles along the blade path helps extract steam for project-specific conditions.

• Design solutions for internally controlled steam extractions are available. Adaptive stage technology is used to control low pressure steam extractions, while intersections with dedicated valves are appropriate for higher pressures.

A200 Turbine Technical Data

Main Steam 140 bar (2031 psi), 565°C (1049°F)

Frequency 50 Hz and 60 Hz

Output ≤ 300 MW

Steam Turbine Efficiency Up to 40.5%

Maximum Backpressure0.35 bar (10.34 inHg) (0.7 bar (20.67 inHg) with special high back pressure rear stages)

Control ConceptSliding pressure modeFixed pressure mode (control stage)Hybrid mode

Powering the World

Page 26: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

STEAM POWER SYSTEMS PRODUCT CATALOG I Generators

GENERATORPortfolio and Overview

GE’s generators are experienced and reliable machines that offer high technical performances. Our

generators have successfully operated in more than 2,000 projects worldwide, providing different

power output levels and cooling media depending on customer need. Designed to help lower plant

investment costs, our generators enhance operation and limit maintenance costs.

Product Families• GIGATOP 2-pole (hydrogen-water-cooled) generators are GE’s enhanced solution for coal power plant

applications. This generator has operated in more than 100 projects since 1973. A power plant in the

Netherlands has the world’s most powerful generator (1,113 MW) running in a coal power plant.

• TOPGAS (hydrogen-cooled) generators are high-efficiency machines. The high power output of this

product family provides a cost-effective alternative to conventional hydrogen-water-cooled machines

that are commonly used for similar high power output levels.

• TOPAIR (air-cooled) generators are precise and robust machines offering high power output

and efficiency. This machine can be used in many different applications.

• TOPACK (air-cooled) generators are ideal for applications demanding simple, packaged and

ready-to-install generators. There are more than 1,500 machines installed worldwide.

46

Product Power Output Range (MW)

510–1,400 MW

400–830 MW

GIGATOP 2-poleHydrogen-water-cooled

TOPGASHydrogen-cooled

70–430 MWTOPAIRAir-cooled

30–170 MWTOPACKAir-cooled

Technologies Bring Added ValueGE’s generators use technologies and contain features that save time and money for the end customer.

Based on many years of proven experience and continuous feedback from our customers, these

technologies often are shared among different product families, as shown in the following three examples.

Tubes in Stainless Steel for Stator-Winding Cooling

Used on GIGATOP 2-pole generator

• The cooling tubes in the stator winding of GE’s GIGATOP 2-pole generator are made of

stainless steel, so they can’t corrode, and the risk of clogging leading to an unplanned

forced outage is eliminated. GE is the only manufacturer to offer this feature.

Self-Retightening End-Winding Support

Used on TOPAIR, TOPGAS and GIGATOP 2-pole generators

• GE’s generators have a self-retightening end-winding support, which allows thermal

expansion of the bars while simultaneously tightening the winding in radial and

tangential directions. This system saves maintenance time for the generator end

user, avoids forced outages, and increases plant availability on the grid.

Concave-Convex Wedges

Used on TOPAIR, TOPGAS and GIGATOP 2-pole generators

• The concave-convex wedges used in GE’s generators have a unique design that

sustains pressure on the stator bars. This constant pressure prevents radial

movements of the winding, avoiding a forced outage from insulation breakdown

while cutting maintenance hours and increasing plant availability.

47

GE’s generators are designed to meet all relevant standards, regulations and grid codes that may apply

in specific 50 Hz and 60 Hz countries. Machines are designed according to IEC and IEEE standards and

are designed for temperature rises of class 130 (B). The insulation, using either DURITENAX or MICADUR*

tape (depending on the product family), fulfills thermal class 155 (F). We perform quality tests and

inspections during manufacturing, delivery, construction and commissioning of the machines to help

ensure high quality and conformance with our customers’ needs.

Powering the World

Page 27: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

GE’s generators have additional design features that enhance technical performance and reduce

maintenance costs:

• Roebel bars in the stator winding reduce losses and heighten efficiency.

• The MICADUR* insulation system is a well-proven insulation tape that helps ensure

high reliability.

• Laminated press-plates and low-loss core laminations enhance efficiency.

The following table summarizes the availability of features within each product family.

48

STEAM POWER SYSTEMS PRODUCT CATALOG I Generators

GENERATOR Portfolio and Overview

GIGATOP 2-pole TOPGAS TOPAIR TOPACK

Stator end-winding support for short maintenance time P P P P

Enhanced stator bars insulation for reliable operation

MICADURVPI

MICADURVPI

MICADURVPI

DURITENAXResin Rich

Concave-convex wedges for reliability and short maintenance time

P P P Ripple Spring System

Enhanced stator core design for low losses and maintenance P P P P

Enhanced seal oil system for low hydrogen losses and high efficiency

Triple-circuit Seal Oil System

Single-circuit Seal Oil System — —

Enhanced cooling system for high efficiency Hydrogen and water Hydrogen Air Air

Skid-mounted auxiliaries that save time on site P P — —

49

Powering the World

Page 28: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

GIGATOP 2-POLE GENERATORReliable Hydrogen-Cooled Generator

High-tech Features for Best PerformanceThe hydrogen- and water-cooled GIGATOP 2-pole generator is used for coal power plants, nuclear full-

speed turbines, and gas power plants and can be found in 100 systems since 1973. Flexible in design,

each machine fits the end user’s power needs with high efficiency. The GIGATOP 2-pole generator has

proven to be highly reliable. For example, a unit in the U.S. boasted 607 days of uninterrupted

operation before a scheduled shutdown.

Based on technology pioneered in the 1970s, the GIGATOP 2-pole generator is constantly improved

with continuous feedback from operational experience worldwide. Designed for both rail and road

transport, the generator has only a small number of individual parts, which translates into

shorter delivery and faster installation time.

50

STEAM POWER SYSTEMS PRODUCT CATALOG I Generators

Features:• High power output levels. For example, the GIGATOP

2-pole generator in the operation in Leibstadt (Switzerland) nuclear plant at 1,190 MW.

• Efficient and flexible. The cooling system sustains a high level of efficiency and has a unique design of press plates for higher reactive power and stabilization in case of grid disturbance.

• Robust and reliable design. The design takes into account normal operation and transcients.

• Continuously evolving technology. The first GIGATOP 2-pole generator was developed in the 1970s and has evolved continuously ever since, based on feedback collected from operating experience.

Applications:• GIGATOP 2-pole generator is well-suited for the

nuclear full-speed Turbine Generator package.

• GIGATOP 2-pole generator represents more than 100 units installed, and its design combines high efficiency, high reliability and optimized maintenance efforts for the benefit of our customers.

51

1 Average reliability calculated according to standard IEEE-762 from measurements collected over nine GIGATOP 2-pole units between 1990 and 2012 by the independent company Strategic Power System

Frequency 50 Hz 60 Hz

Power Factor 0.8 to 0.9 0.85

Apparent Power 590 MVA to 1400 MVA 510 MVA to 1120 MVA

Efficiency Up to 99% Up to 98.9%

Terminal Voltage 18 kV to 27 kV 22 kV to 26 kV

Reliability1 99.996%

First 1,000 MW Coal Plant in China from GE Since the rail network in China has narrow tunnel profiles and load restrictions, a specific GIGATOP 2-pole generator was designed to fulfill all of China’s specific technical and rail transportation requirements for dimensions and weight.

Powering the World

Page 29: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

TOPGAS GENERATORBest-in-Class Hydrogen-Cooled Generator

TOPGAS hydrogen-cooled generators benefit from a strong heritage of technology and extensive

operational feedback. The TOPGAS power output range is a cost-effective alternative to bigger and

more complex hydrogen-water-cooled generators.

Today’s TOPGAS generator power output range goes beyond 710 MVA (ca. 600 MW), so the generator

can be installed in power plants that generally would require more complex hydrogen-water-cooled

generators, such as conventional 660 MW coal power plants. By offering a lower investment cost and

higher efficiency than conventional hydrogen-water-cooled generators, the TOPGAS generator reduces

electricity costs and emissions.

52

STEAM POWER SYSTEMS PRODUCT CATALOG I Generators

Features• Lower investment cost, derived from the high power

rating and the generator’s efficiency. TOPGAS machines are a cost-effective alternative to more complex hydrogen-water-cooled generators that normally are used for similar power output levels

• Excellent 99.7 percent reliability, based on measurements collected from 34 TOPGAS units between 1998 and 2012

• High efficiency of around 99 percent, mainly because of the enhanced winding and hydrogen cooling system

• Easy to maintain, thanks to specific design features of the stator bar wedging and stator end-winding support parts

53

1 Average reliability calculated according to Standard IEEE-762 from measurements collected from 34 TOPGAS units between 1998 and 2012 by the independent company Strategic Power System.

TOPGAS in High Cyclic Operation A TOPGAS unit in a 400 MW gas-fired combined cycle plant, powering a Japanese steel production facility, has been operating reliably in daily start-stop mode since September 2002, accumulating more than 2,050 starts and more than 48,000 operating hours.

Frequency 50 Hz 60 Hz

Power Factor 0.8 0.85

Apparent Power 400 MVA to 830 MVA 450 MVA to 615 MVA

Efficiency Up to 98.9% Up to 99%

Terminal Voltage 18 kV to 23 kV 19 kV to 23 kV

Reliability1 99.715%

Powering the World

Page 30: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

TOPAIR GENERATORPrecise and Robust Air-Cooled Generator

The most powerful air-cooled generator in operation today, GE’s TOPAIR unit has accumulated worldwide operational experience from more than 570 installations. It is a robust machine providing high reliability and maintainability.

TOPAIR air-cooled generators have a power output range that usually is found in larger and less cost-effective hydrogen-cooled generators. This is the result of continuous, evolutionary development that has pushed the limits of power output while enhancing efficiency and controlling investment costs. At the same time, it is simple and easy to operate and maintain.

The flexible TOPAIR, because of its short production time (parallel manufacture of stator and casing, pre-assembly, and ease of transport), is a generator that can be up and running quickly. This reduces construction and commissioning time and accelerates plant revenue flow.

TOPAIR units are available in standardized sizes, with different capabilities and performances.

54

STEAM POWER SYSTEMS PRODUCT CATALOG I Generators

Features• Cost advantage due to high power rating and efficiency,

over hydrogen-cooled generators

• Continuous improvement from the latest advanced technology, including enhanced power range and efficiency at limited product cost

• Proven operational flexibility from demonstrated robustness and reliability over many years in all operation modes

• Extensive worldwide operational experience with more than 570 units installed worldwide

55

1 Average reliability calculated according to Standard IEEE-762 from measurements collected from 304 TOPAIR units between 1990 and 2012 by the independent company Strategic Power System.

TOPAIR Working in a Tough Environment More than 200 TOPAIR generators have been installed in the Middle East, where their durability and robustness are tested to the limit by extreme operating conditions. For example, 32 TOPAIR units have been operating in Saudi Arabia since 1978. Bahrain is host to the world’s largest air-cooled generator, which has been operating since 1999 and has accumulated more than a million operating hours.

Frequency 50 Hz 60 Hz

Power Factor 0.8 0.85

Apparent Power 70 MVA to 430 MVA 80 MVA to 360 MVA

Efficiency Up to 98.9% Up to 98.8%

Terminal Voltage 11.5 kV to 22 kV 13.8 kV to 22 kV

Reliability1 99.911%

Powering the World

Page 31: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

TOPACK GENERATORPackaged Air-Cooled Generator

The air-cooled TOPACK generator is remarkable for its breadth of customer advantages and its accumulated experience.

The packaged TOPACK solution comes complete with all necessary electrical equipment, saving our customers time, effort and money. Compact and modular, based on standardized manufacturing processes, a TOPACK generator quickly gives our customers exactly what they need. It is delivered as a single unit that is ready to install, simple to integrate into the power plant, and easy to maintain.

The TOPACK generator is highly reliable, with a wide power range that is versatile enough to handle all kinds of applications – indoor or outdoor and in a variety of climates.

TOPACK generators are available in standardized sizes, with different capabilities and performances.

56

STEAM POWER SYSTEMS PRODUCT CATALOG I Generators

Features• Fully packaged generator that comes complete

with all electrical systems

• Reliable and robust product, with more than 1,300 installations worldwide and proven in many different environments

• Compact size and easy maintenance for quick and easy transportation and installation

57

Extreme Operating Conditions A refinery in Kazakhstan is located at one of the largest oil field in the world and faces extreme ambient temperatures reaching -36°C. Two TOPACK units are installed there to produce electrical power and these machines have operated reliably for more than 10 years.

Frequency 50 Hz 60 Hz

Power Factor 0.8 0.85

Apparent Power 35 MVA to 200 MVA 35 MVA to 200 MVA

Efficiency Up to 98.7% Up to 98.6%

Terminal Voltage 11 kV to 15 kV 13.8 kV

Powering the World

Page 32: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

North AmericaPower 160 GWIndustry 360 Systems

Latin AmericaPower 7 GWIndustry 230 Systems

EuropePower 113 GWIndustry 1,600 Systems

Middle East and AfricaPower 40 GWIndustry 160 Systems

Russia and CISPower 13 GWIndustry 80 Systems

AsiaPower 98 GWIndustry 1,800 Systems

IndiaPower 50 GWIndustry 700 Systems

OceaniaPower 20 GWIndustry 120 Systems

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

AIR QUALITY CONTROL SYSTEMS (AQCS)Portfolio and Overview

Pioneer in Air Quality Control for Power and Industrial ApplicationsWe have provided our customers with advanced Air Quality Control Systems (AQCS) for more than

80 years. GE’s expertise, technology and comprehensive product portfolio enable our customers to

comply with today’s stringent emission regulations for particulate and gaseous pollutants emitted

from power plants and industrial operations. Our high quality and cost-effective equipment and services

can be adapted to our customers’ needs.

58 59

Our Success:

500 GWIn Power Applications

5,000Units in Industrial Applications

More than 80 years of experience providing advanced emission controlsAt GE, we:• Help our customers determine the best combination of technologies for their

specific site requirements

• Offer a range of products to comply with today’s stringent emissions regulations

• Deliver a variety of AQCS on an engineering, procurement and construction (EPC) or engineering and procurement (EP) basis

• Provide after-sales services including spare parts, inspection and remote monitoring

• Offer a variety of solutions to upgrade our customers’ existing equipment with our latest innovations for improved performance and/or lower operating costs

Powering the World

Page 33: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

AIR QUALITY CONTROL SYSTEMS (AQCS)Portfolio and Overview

60 61

Customized OfferingsWith GE, customers receive a wealth of air quality control know-how. For new built

and upgrade and retrofit of existing AQCS, we offer on-demand solutions tailored to

meet our customers’ requirements, including partial or full scope as described below:

• Engineering. GE offers advanced air pollution control engineering, from process

and equipment design to construction, operations and maintenance.

• Equipment supply. Our comprehensive AQCS portfolio of products covers a

broad range of pollutants with industry leading technology with a single process or

a combination to cover the entire flue gas chain. This gives customers the flexibility

to address complex interactions between components and processes.

• Construction and commissioning. We offers:

— Construction management

— Commissioning management

— Construction and commissioning advisory services

• Inspection and maintenance. We provide these services for

our own fleet and/or other AQCS solutions.

Innovative Products and TechnologiesSince 1983, our technology center in Växjö, Sweden – one of the largest in the world in the field of

environmental control solutions – has been at the forefront of advanced research and development for

air quality and CO2 control solutions. Focusing on technology innovation and product validation, it has

test halls for pilot operations and flow modeling, an analytical laboratory specializing in particle and

environmental analyses, an instrument workshop, high voltage facilities for ESP electrical testing (SIR,

T/R sets), and a mechanical workshop for pilot equipment manufacturing.

Powering the World

Page 34: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

Electrostatic precipitators (ESPs) represent a very large installed base worldwide in terms of particulate

emission control, and GE offers a wide range of robust, cost effective and reliable ESP designs for a variety

of applications. Backed by decades of experience on an extended range of fuel combinations and industrial

applications, our solutions cater to increasingly strict regulations at a lower life cycle cost. We offer:

• Spiral and rigid designs of emitting electrodes, tumbling hammer and electric impact

rapping systems

• Flexible layout and modular designs suited to the site

• Integrated ESP control systems, including the latest generation EPIC intelligent controller and the

ProMo tool for enhanced ESP performance

• Switch Integrated Rectifiers (SIR) as an alternative to Transformer/Rectifier (T/R) sets for increased

power input, lower power consumption and improved particulate removal efficiency. Ideal for

performance enhancement of existing ESPs.

62 63

1 Industry- Cement: Kiln, Mills, Cooler; Iron & Steel: Sintering, Pelletization, Sponge Iron Kiln, Cast House, Stock House; Biomass fired boilers; Waste to Energy plants; Pulp & Paper: Recovery Boiler, Lime Kiln; Non-Ferrous- Smelter, Converter; Oil & Gas: FCCU et. al.

2 Industry - Iron & Steel- Blast Furnace, Iron & Steel- Scarfing, Iron & Steel- Converters, Aluminium- Anode Baking

GE has installed seven ESPs in Europe’s largest power station based in Poland. Six of the units are of 370 MW capacities and the latest unit is of 858 MW capacity, all firing lignite fuel. The six ESPs of 370 MW are designed with multiple electrode spacing (400 mm and 500 mm) in the front and rear fields – an advanced concept developed by our ESP experts at our R&D center in Vaxjo, Sweden. Multiple spacing helps in saving both capital expenditure and operational costs of the ESPs while maintaining the emission performance. Two of the units were recently commissioned and have successfully achieved emissions of less than 10 mg/Nm3.

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

Dry ESPParameter Number

Applications Power-Boilers and Heaters, Industry1

Power Capacity (MW) 10 to 1300

Gas Temperatures (°C) 70 – 400

Gas Flow Rate (m3/s) 15 – 2000

Dust Loading at ESP inlet (g/Nm3) 0.2 – 100 g/Nm3; for SDA 600 g/Nm3; for NID 1800 g/Nm3

Emission at ESP outlet (mg/Nm3) 10 – 200 (exceptional 1000 for ESP as precollector), filterable PM only

PM Removal Efficiency Up to 99.95%

Availability Up to 98%

Wet ESPParameter Number

Applications Power-Boilers, Heaters, Synthesis Gas and Industry2

Gas Temperatures (°C) Up to 70 C , Saturated Gas

Gas Flow Rate (m3/s) 15 – 2000

Dust Loading at ESP inlet (g/Nm3) Up to 1.2

PM Emission at ESP outlet (mg/Nm3) 0.5, filterable PM only

SO3 Emission (ppm) <1 ppm

PM & SO3 removal efficiency 99%

Availability Up to 98%

PARTICULATE CONTROLDry and Wet Electrostatic Precipitators (ESPs)

Key Features of Dry ESP• Proven particulate matter removal for power and

industry applications

• Less than 10 mg/Nm3 emissions

• More than 237 GW installed in power generation and 70-plus years of experience

• Excellent and efficient design with lower cost modular systems

In addition to dry ESP technology, GE also offers horizontal wet ESPs for specific applications such as power, metallurgy, and waste to energy.

Key Features of Wet ESP• Ultra-low particulate emissions (less than 1mg/Nm3), acid mists, aerosols, hazardous air pollutants (HAP)

• More than 80 references for various applications

Powering the World

Page 35: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

PARTICULATE CONTROL Fabric Filters

Operational and fuel flexibility are increasingly important today, even as air quality regulations are becoming

more stringent. For particulate removal, fabric filters offer a flexible alternative to electrostatic precipitators

(ESPs), particularly when dust characteristics are challenging or variable. GE offers both high ratio (pulse jet)

and low ratio (reverse air) options, depending on the application.

Fabric filters may be used stand-alone or integrated in Dry Flue Gas Desulfurization (DFGD) solutions (NID*

or SDA), for dry scrubbing in the aluminum industry (Abart*), or as the principal and polishing filters in

mercury control solutions (Mer-Cure* or Filsorption*).

64 65

Fabric FiltersParameter Number

Types Pulse jet filters and Reverse air filters

Applications Power – Boilers and Heaters, Industry1

Power Capacity (MW) 10 to 1000

Gas Temperatures (°C) 25 – 260

Gas Flow Rate (m3/s) 10 - 1500

Dust Loading at FF inlet (g/Nm3) 2 – 100; for NID up to 2000

Emission at FF outlet (mg/Nm3) 5 – 50 wet @ operating O2 level (dry filterable particulate only), filterable PM only

Availability (%) Up to 99%

Bag Life Guarantee (Years) 1 to 6 depending on application and filter type

1 Industry- Cement: Kiln, Mills, Cooler; Auxiliary dedusting, Iron & Steel: sintering, pelletization, cast house, stock house, coke oven; Biomass fired boilers; Waste to Energy plants; Pulp & Paper: lime kiln et.al.

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

Key Features• Lower than 5 mg/Nm3 particulate emissions possible,

greater than 99.97 percent particulates removal efficiency, high PM10 and PM 2.5 removal rate

• More than 45 GW installed base in power applications

• Filters up to 12 meters tall for reduced footprint and operational costs

• Bag life in excess of five years achieved

• Large fuel flexibility and ability to handle varying boiler loads

• Renowned Optipulse* filtration technology with gravimetric flow and Optipow* plunger valves for efficient bag cleaning

• Stand-alone or integrated in multi-pollutant systems

• Latest EFFIC controller and ProMo software for superior FF performance

• The combination of Optipow valves and EFFIC controller on a new or existing fabric filter provides better bag life compared to other solutions available in the market

Optipulse Mega Fabric Filters After successfully installing and operating electrostatic precipitators on its three initial 700 MW units, a leading power plant in Malaysia decided to apply mega fabric filters with Optipulse technology and 10-meter-long bags for its fourth 1,000 MW unit. The fabric filter was designed to offer low emissions across varying input conditions. The stack emission during the recently conducted PAC of Unit 4 was measured at less than 5 mg/Nm3.

Powering the World

Page 36: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

66 67

DFGD (NID) Parameter Number

SO2 Removal Rate (%) Up to 98

SO3 Removal Rate (%) Up to 95

HCl Removal Rate (%) Up to 95

HF Removal Rate (%) Up to 95

Maximum SO2 Content at Inlet (mg/Nm3)

10,000

Particulate Emission Guarantee (mg/Nm3)

10

Fuel Applicable for all fuels

Max Inlet Temperature (°C) 200

Load Range per Module (%) 50 - 100

Reagent Ca(OH)2 or CaO

Availability (%) Up to 97

In response to multi-pollutant emissions regulations from the Massachusetts Department of Environmental Protection, a leading energy company in Somerset installed our NID on one of its units. The modular design of the NID allows the plant to operate at 20 percent without flue gas recirculation and with one module out of service, without any impact on boiler operation.

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

SOx CONTROL Dry Flue Gas Desulfurization (DFGD)

Dry desulfurization systems have been used for SOx control and multi-pollutant control for several

decades. They are generally based on lime utilization as sorbent, and the end product is dry with no

need for important waste water treatment as compared to wet systems.

GE’s portfolio of dry flue gas desulfurization (DFGD) solutions includes:

NID*

This system is made up of a patented integrated hydrator/mixer, a J-duct reactor and typically a fabric filter.

Hydrated lime is used as a reagent to react with gaseous pollutants like SOx, HCl and HF. Mercury collection

can be realized by injecting PAC upstream. The collected particles are either recirculated or disposed.

Key Features• More than 20 years of successful commercial operation, 15 GW installed for power applications

• Up to 98 percent SO2 removal, up to 4 percent sulfur in coal, multi-pollutant control

• Compact footprint of less than 50 percent, compared to Spray Dryer Absorber (SDA)

• Modular and standard design for lower construction costs and eligible for small projects up to very large power plant size

• Simple operation and maintenance; low operational costs

• A well-fitted technology for various industry applications, in particular waste-to-energy, iron and steel

Spray Dryer Absorber (SDA)

This conventional dry FGD system is made up of a reactor followed by a fabric filter. In the reactor,

the reagent slurry solution is atomized using either GE’s rotary atomizer technology or dual fluid

nozzles, and the droplets react with the gaseous pollutants in the flue gas stream.

Key Features• More than 35 years of experience, 15 GW installed capacity for power

and industry applications

• Up to 95 percent SO2 removal, up to 2.5 percent sulfur in coal

DFGD (SDA) Parameter Number

SO2 Removal Rate (%) Up to 95

SO3 Removal Rate (%) Up to 95

HCl Removal Rate (%) Up to 95

HF Removal Rate (%) Up to 95

Maximum SO2 Content at Inlet (mg/Nm3)

6,000

Particulate Emission Guarantee (mg/Nm3)

10

Fuel Applicable for all fuels

Max Inlet Temperature (°C) 260

Load Range per Module (%) 15 - 100

Reagent Ca(OH)2 or CaO

Availability (%) Up to 98

Powering the World

NID

Page 37: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

Wet flue gas desulfurization (WFGD) has been the most common technology for SOx control for

more than four decades.

GE’s WFGD portfolio consists of the following options:

WFGD-Open Spray Tower (OST)

The third generation WFD-OST operates over a range of 300 to 1,300 MW. The system offers lower power

consumption and has smaller dimensions compared to previous generations, while reaching nearly zero

emissions. The gypsum by-product recovered is usable as wallboard or cement quality.

GE’s Flowpac WFGD is designed for unit sizes up to 360 MW. In this turbulent bed absorber, flue

gas passes through limestone slurry. It is targeted for applications with fuels having medium to high

sulfur content and requiring increased SO2 and SO3 removal efficiency. In addition, it is well suited for

varying fuel conditions.

Key Features• Approximately 58 GW installed capacity

• Flexible absorber performance with controllability of the SO2 removal rate

• Improved performance control through patented sulfite analyzer

• Fuel flexibility for all types of fuel (including heavy fuel oil) with sulfur content up to 4.5 percent for WFGD-OST and up to 6 percent for Flowpac WFGD

• Lower power consumption with lower emissions of particulates and aerosols

Sea Water FGD (SWFGD) Technology

GE’s SWFGD is a unique no by-product SO2 removal solution. Thanks

to more than 40 years of experience in SWFGD technology for power

generation and industry applications, we are one of the leading

providers of SWFGD for power generation and industry applications.

Key Features• An economical desulfurization solution for plants in coastal areas

• Approximately 51 GW in operation or under construction for a variety of applications and a wide range of fuels

68 69

In 2015, we successfully commissioned our SWFGD solution at a leading coal-fired power plant in Malaysia. It is the first 1,000 MW plant in Malaysia and the single largest unit in Southeast Asia. The SWFGD system lowers SOx emissions over a wide load range, helping the plant meet its environmental responsibilities.

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

SOx CONTROLWet Flue Gas Desulfurization (WFGD)

SWFGD Parameter Number

Maximum Gas Flow Rate – per Absorber (Nm3/h)

3,400,000

Power Plant Size (MW) up to 1,000

FuelCoal, lignite, oil, HFO, industrial processes

Maximum SO2 Content at Inlet (mg/Nm3)

15,000

SO2 Removal Rate – with GGH (%)

98

Load Range (% MCR) 20 - 100

Seawater Temperature Inlet to Absorber (°C)

4 - 45

Alkalinity – Minimum (mmol/l) 1.2

pH Seawater Inlet (minimum) 7.7

WFGD-OST Parameter Number

Maximum Gas Flow Rate – per Absorber (Nm3/h)

3,200,000

Power Plant Size (MW) up to 1,300

FuelCoal, lignite, oil, HFO, industrial processes

Maximum SO2 Content at Inlet (mg/Nm3)

17,000

SO2 Removal Rate (%) > 99 achieved

Load Range (% MCR) 20 -100

HCl Removal Rate (%) > 99

HF Removal Rate (%) > 99

ReagentLimestone, lime or sodium

Powering the World

Page 38: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

GE’s Selective Catalytic Reduction (SCR) technology controls nitrogen oxides (NOx) formed in combustion

processes. With more than 30 years of experience with SCR technology for power generation and industry

applications, GE’s lower cost DeNOx solutions help customers reach their requested performance

levels. High NOx reduction rates and system reliability make our flexible and compact SCR technology

the choice for post combustion NOx control.

71

In July 2008, GE’s technology was chosen by the main power producer in Portugal to retrofit four SCR units at a power plant in southern Portugal. These SCR units are designed for 81 percent NOx removal efficiency and use heated ammonia solution as the reagent and a vanadium/titanium honeycomb catalyst.

With these SCR units, Portugal has become one of the few countries in Europe to have equipped all of its coal-fired plants with systems to control both SOx (sulfur oxides) and NOx, thus meeting European Union emission targets.

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

SCR Parameter Typical Information

Reactor Size 3,200,000 acfm, 5,400,000 m3/h

Fuel Type Gas, fuel oil, orimulsion, pet coke, biofuel (virgin wood or peat), coal

Reactor Position High dust SCR for power plants and CHP plants; tail end SCR for waste incinerators

Reactor Flow Direction• Coal applications: vertical down• Oil applications: vertical up or vertical down• Gas applications: vertical up or vertical down and horizontal

Cleaning Method Soot blower using steam or compressed air, sonic air horns, air sweepers

NOx Removal Efficiency Up to 95%

NH3 Slip 2 vppvd @ 3% O2

Operation Temperature570-815°F, 300-435°C for coal/oil 450-850°F, 230-435°C for gas

NOx Inlet Concentration 2050 mg/Nm3

O2 1% minimum

SO2 3,500 ppm

SO2/ SO3 Conversion 0.5 - 2.0%

Ash Load 35,000 mg/Nm3

Reagent Type Anhydrous ammonia, aqueous ammonia, urea

NOx CONTROLSelective Catalytic Reduction (SCR)

70

Key Features• More than 48 GW installed with more than 80

installations

• Up to 95 percent NOx removal, low ammonia slip (less than 2 ppm)

• Proprietary IsoSwirl* mixing technology and specific ammonia injection grid design for improved performances

• Partnerships with leading catalyst suppliers

• Design tailored to existing site conditions for reduced outage time

Powering the World

SCR on a steam power plant

Page 39: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

With the knowledge gained from our more than 80 years of experience designing larger sized units,

GE has developed the Smartline range of products to cater to smaller-sized applications such as

district heating, small power units, thermic fluid heaters, lime kilns, foundries, and metallurgical

plants. Key features of our Smartline solutions include:

• Standard and modular designs, which can be pre-assembled

• Easily transportable

• Lower cost and simple installation

FABPAC Fabric Filters for Particulate Control

These standardized and modular fabric filters can help our customers lower operational cost and

footprint and reduce site installation time. Our patented Optipow* cleaning valves together with

EFFIC controllers provide longer bag life and lower compressed air consumption. FABPAC filters are

available in four standardized sizes with various bag lengths and bag materials.

ELPAC ESPs for Particulate Control

The ELPAC ESP adapts the benefits developed on large units to a smaller scale. Key features include:

covered service room on top, flat bottom with scraper conveyor, Switch Integrated Rectifiers (SIR),

efficient construction for easy access, and large gas flow range with one module

(7000-170,000 m3/hr).

Micro-NID* Technology for Dry Desulfurization

and Multi-pollutant Control

Due to its simple design, our advanced dry desulfurization

technology is also available for small-scale applications. With more

stringent regulations being progressively extended to smaller

units, this type of application is expected to be widely deployed

in the coming years.

72 73

SMALL SIZE AQCSSmartline Solutions

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

GE supplied two ELPAC ESPs on a 4 MW boiler and an 8 MW boiler that were firing bio-fuels such as forest residues and wood chips at a CHP project in Norway. Designed for an emission guarantee of 50 mg/Nm3, these ESPs were delivered to the customer within five months and installed in just four weeks. Both units are performing well and achieving emissions lower than what was guaranteed.

FABPACGas Temperatures (°C) 25 - 200

Gas Flow Rate (m3/h) Up to 250,000

Dust Loading at FF inlet (g/Nm3) 2 – 100

Emission at FF outlet (mg/Nm3) 5 - 50, filterable PM only

Availability (%) Up to 99%

ELPACGas Temperatures (°C) 70 - 250

Gas Flow Rate (m3/h) Up to 170,000

Dust Loading at FF inlet (g/Nm3) 1 – 50

Emission at FF outlet (mg/Nm3) Up to 20, filterable PM only

Availability (%) Up to 98%

Micro-NID*

Maximum gas temperature at inlet (°C) 200

Outlet Emission Limit, HCl (mg/Nm3) 2

Outlet Emission Limit, HF (mg/Nm3) 0.3

Outlet Emission Limit, SO2 (mg/Nm3) 5

Outlet Emission Limit, Particulate (mg/Nm3) 5

Outlet Emission Limit, Hg (mg/Nm3) 0.03

Outlet Emission Limit, Dioxin (ng/Nm3) 0.05

Maximum Gas Flow rate (Nm3/h) 10 0001

1 For higher gas flow rates, standard NID will apply.

Powering the World

Page 40: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

In addition to addressing the most common pollutants, such as particulate

matter, SOx and NOx, GE offers solutions for capturing other pollutants.

Mercury

The Filsorption* system uses activated carbon injection upstream of a

standard primary or secondary particulate control system.

The Mer-Cure* system uses a proprietary approach injection of sorbent

upstream of the air preheaters, for faster oxidation under higher temperatures.

• More than 25 years and 29 GW installed

• More than two million hours of reliable operation

Volatile Organic Compounds (VOC)

For VOC mitigation, GE provides thermal oxidizers and regenerative thermal

oxidizers – mature technologies that have been sold for many decades.

Zero Liquid Discharge (ZLD)

Additionally, GE offers our Spray Dryer Evaporator (SDE*) solution for plants

operating WFGD technologies to achieve Zero Liquid Discharge (ZLD). Our

simple and cost effective SDE technology uses hot flue gas to evaporate

waste water. The dissolved or suspended solids are collected in existing

particulate removal equipment. With the addition of lime to condition the

waste water feed stream, acid gases in the flue gas can be captured as

an added benefit.

74 75

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

OTHER AQCS SOLUTIONSMercury, VOC, Zero Liquid Discharge

MERCURY CONTROLFilsorption* for Power (typical)

Parameter Number

Fuel Boiler flue gas

ReagentActivated carbon or activated lignite coke and/or non-carbon sorbents

Bromine InjectionOptional depending on the halogen content in the coal

Removal Efficiency (%) Up to 92

Temperature (°C) 200

PAC Addition Rate (kg/106 Nm3/h)

50 - 200

ZERO LIQUID DISCHARGE SDE* for Power (typical)

Parameter Number

Evaporation Rate (m3/h) 5 - 35

Wastewater TDS (mg/l) Up to 140,000

Wastewater TSS (%) Up to 20

Gas Flow Rate (Nm3/h) Up to 175,000

Max Inlet Temperature (°C) 400

Load Range per Module (%) 30 - 100

Availability (%) Up to 97

VOC CONTROLThermal Oxidizer

Parameter Number

Gas Flow Rate (Nm3/sec) 0.2 – 20

VOC Concentration (% of LEL) 0 – 25

Load Range (%) 33 – 100

Dust Load (mg/Nm3 wg) Max 2.0

Operating Temperature (°C) 760 – 900

Oxygen content in Process Gas (%) 10 – 21

VOC Destruction Efficiency – Applicable for VOC Content Between 1000 ppm and 25% LEL (%)

Max. 99.5

VOC Emission Applicable for VOC content below 1000 ppm (ppm)

Min. 5

Availability (%) Up to 98

Regenerative Thermal OxidizerParameter Number

Gas Flow Rate (Nm3/sec) 0.5 – 50

VOC Concentration (% of LEL) 0 – 25

Load Range (%) 33 – 100

Dust Load (mg/Nm3 wg) Max 2.0

Operating Temperature (°C) 815 – 1,000

Oxygen content in Process Gas (%) 8 – 21

VOC Destruction Efficiency – Applicable for VOC Content Between 1000 ppm and 25% LEL (%)

Up to 95 - 99.5

VOC Emission Applicable for VOC content below 1000 ppm (ppm)

Down to 5 - 50

Availability (%) Up to 98

Powering the World

Page 41: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

76 77

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

SOLUTIONS FOR EXISTING AQCS

A Brazilian customer replaced its conventional T/R sets with new high frequency power supplies (SIR) and control systems (EPIC). Emissions at the stack were reduced from 80 mg/Nm3 to 40 mg/N m3. Furthermore, the reliability of the equipment improved significantly, as did system life.

Plant operators today face various challenges such as cost reduction, compliance with more stringent environmental regulations, and the need for improved plant flexibility. With an understanding of these challenges, GE uses our knowledge of AQCS technology and continues to innovate, offering a full range of:

• Upgrades and retrofit solutions for our customers’ existing AQCS equipment

• Services and parts for operation and maintenance

Some of our key solutions for enhancing performance of existing AQCS include:

• High-frequency power supplies - switch integration rectifiers (SIRs) for ESPs

• Emissions and energy optimization algorithms, like EPOQ software, for various AQCS equipment types

• Advanced control systems - EPIC for ESP and EFFIC for fabric filters

• Superior diagnosis using ProMo software

SIR Technology

Our SIR technology combines a transformer/high

voltage rectifier (T/R) and a control system for energizing

and controlling ESPs in one compact integrated unit.

With an integrated rapping control and EPOQ software

for pulse optimization, the SIR controller takes the ESP’s

performance to the next level.

Key Features• Suitable for installation on new or existing ESPs

from GE and also other OEMs

• More than 3,500 SIR units in operation around the world; solution developed in the 1990s

• Reduces up to 70 percent particulate emissions compared to conventional technology, and emission levels reduced down to below 20 mg/Nm3, when required

• Determines top power consumption

• Avoids cost-intensive retrofit

• Suitable for ESPs in power and industrial applications, such as cement and pulp & paper

Sulfite Analyzer for WFGD

Our new patented solution provides real-time

measurement and control of the sulfite

concentration in the slurry, allowing for reduced

power consumption from the blower. Designed to

cope with harsh environments in heavy industrial

applications, our Sulfite Analyzer can be installed in

the existing slurry slip stream with no need for an

outage or process alteration.

Switch Integrated Rectifiers (SIR)Model SIR4 120 kW SIR4 102 kW

Sizes Available HV70 kV – 1700 mA, 85 kV – 1400 mA, 100 kV – 1200 mA

70 kV - 1500 mA, 85 kV - 1200 mA

Power Supply Input (3-phase rectifier)

50 Hz 400 V - 196A, 500V - 157 A 380 V - 180A, 400 V - 175A60 Hz 480 V -163 A, 575 V - 136A 480 V - 146 A

Operating Temperature -40ºC to +40ºC max 50ºC with reduced output current

-25ºC to +40ºC max 50ºC (122ºF) with reduced output current 45ºC with nominal output for 480 V, 60 Hz

Size (w x d x h) 845 x 1300 x 1210 mm (33,3 x 51,2 x 47,6 in)Weight 450 - 500 kg

Dielectric TypeMineral Transformer Oil Nynas Nytro 10XN, vacuum degasified

Solutions for performance improvement of existing AQCS Equipment – GE & Other OEMsProduct Equip-

ment Functionality Key Benefits

SIR ESP ESP Power Supply Emission & energy optimization

EPIC ESP TR Controller Emission & energy optimization

ERIC ESP Rapper Controller Control of electric impact rappers

EFFIC FF FF Controller Air consumption & bag life enhancement

Optipow FF Pulse Valve Superior pulsing performance for bag cleaning

ProMo4 ESP/FF/FGD Monitoring & Control Software Performance tuning & analytical tool, remote connectivity

ETU ESP/FF/FGD Human Machine Interface Hand-held unit for controller settings, input & display

PCETU/PCMTU ESP/FF/FGD Human Machine Interface PC-based unit for controller settings, input & display

IM300 ESP/FF/FGD Protocol Convertor Flaktbus to ethernet converter

AGDMS ESP Gas Distribution(GD) Measurement Tool Robotic device for automated gd measurement

Ammonia Injection Skid ESP Ammonia Injection in Flue Gas Stream Performance improvement of esp using ammonia injection

Powering the World

Page 42: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Success Story

Products

APPLICATIONParticulate -FF

Particulate -ESP

DeSOx- DFGD

DeSOx- WFGD/ SWFGD

DeNOx- SCR

VOC- TO / RTO / KemPAK

Mercury - Mercure /Filsorption

Oil & Gas

FCCU P P P P

Boilers/Heaters P P P P P

Tank farms/Odour/Flares P P P P P

Captive Power P P P P P P

Sour Gas Incineration P P P P P

Catalyst Recovery Unit P P P P

SRU/TGTU P P P P

Waste To Energy Incinerators P P P P P P

Iron & Steel

Iron Ore Sintering P P P P

Iron Ore Pelletization P P P P

Sponge Iron Kiln P P P

Stock House Ventillation P P

Cast House Ventillation P P

Auxiliary Dedusting P P

Induction Furnace P

Electric Arc Furnace P

Blast Furnace P

Boilers/ Captive Power Plant P P P P P P

Cement

Cement Kiln P P P P P

Cement Mill P P

Clinker Cooler P P

Coal Mill P P

Auxiliary Dedusting P P

Boilers/ Captive Power Plant P P P P P P

Pulp & Paper

Soda Recovery Boiler P

Lime Kiln P P

Biomass Boilers/Heaters P P P P P P

Non- Ferrous

Smelter P P

Converter P P

Auxiliary Dedusting P P

Aluminum

Non-Ferrous Metal

Iron/Steel

Pulp and Paper

Waste to Energy

Biomass PetrochemicalsOil and Gas

Cement

8 Industries Covered

GE’s advanced Air Quality Control Systems are also used in a variety of industrial applications, including

iron and steel, cement, waste-to-energy, biomass, pulp and paper and non-ferrous metals. At GE we

address pollutants such as particulates, SOx, NOx, acid compounds, heavy metals, dioxin and furans.

Additionally, we have developed special products to mitigate emissions such as HAPs (Hazardous Air

Pollutants), VOCs (Volatile Organic Compounds) and H2S.

78 79

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

AQCS FOR INDUSTRYSolutions for Industrial Applications

A leading cement manufacturer in India decided to expand its cement plant in the Indian state of Rajasthan. The manufacturer chose our AQCS equipment including Raw Mill Kiln Reverse air bag house, Clinker Cooler ESP, and Coal Mill fabric filter, all of which are designed for emissions of 30 mg/Nm3. The equipment was successfully commissioned along with the entire plant in 2015.

Key Benefits• Technically reliable and cost-effective solutions

• Product expertise leading to solutions that meet customer requirements

• Waste to energy: tailored and efficient solutions to help meet the most stringent emission requirements to both air and water, and at the same time recover valuable energy

• Pulp and paper: advanced ESP and fabric filter technology applied worldwide for emission compliance

• Iron, steel and non-ferrous: primary and secondary steelmaking (coking plants, sintering plants,ore beneficiation, pig iron production, oxygen steel plants, electric arc furnaces, rolling mills) as well as smelting furnaces and converters for various non-ferrous productions

• Petrochemicals-oil and gas: allowing the petroleum and refining industry to conform to strict emission limits while processing a broad feedstock slate

• Cement: single source for cement industry for multi-pollutant emission control with proven technologies such as FF, ESP and FGD systems

Powering the World

Page 43: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Key Demonstration Projects

Oxy-Combustion• 30 MWth, Germany (lignite)• 30 MWth, France (gas)• Boiler Simulation Facility, 15 MWth, U.S. (coal)• Mobile GPU Unit

Post-CombustionChilled Ammonia Process• 5 MWth, Sweden (oil)• 40 MWth, Norway (gas & FCC �ue gas)• 58 MWe, U.S. (coal)• 5 MWth, U.S. (coal)

Post-CombustionAdvanced Amines Process• 5 MWth, France (coal)• 2 MWth, U.S. (coal)

STEAM POWER SYSTEMS PRODUCT CATALOG I CO2 Capture Solutions

CO2 CAPTURE SOLUTIONS (CCS) Building a Low Carbon Future

As a leader in the development of both cleaner coal technologies and Air Quality Control Systems, GE is at the forefront in the development of carbon capture technologies. With an intensive research and

development program, we have designed and constructed 13 CO2 Capture Solutions (CCS) demonstration projects around the world, and these technologies are ready for large-scale implementation.

Given the variety of plant types and fuel combinations in operation today, GE’s portfolio of technologies provides our customers with solutions that take into account many variables, including installation costs, overall plant efficiencies, and operation and maintenance costs. Our CCS technologies offer both post-combustion and oxy-combustion solutions for applications covering new build plants and the existing installed base. Additionally, our post combustion technologies can be scaled down for industrial flue gas from sources such as steel mills, cement factories, refineries and chemical plants. We are also developing second-generation technologies such as Regenerative Calcium Cycle (RCC) and Chemical Looping Combustion (CLC).

What We Offer

Our CCS services range from concept engineering and feasibility studies to plant commissioning. Our

full scope of solutions includes design, equipment supply, installation, power block system integration,

CO2 capture and processing equipment, and the full power plant. We make sure our customers have

everything they need, including cost control, quality control, health and safety and O&M training.

80 81

Powering the World

• All types of offerings for

oxy- and post-combustion

technologies

• Most comprehensive pilot/

demo portfolio

• Reliable technologies,

ready for scale-up

Page 44: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

STEAM POWER SYSTEMS PRODUCT CATALOG I CO2 Capture Solutions

OXY-COMBUSTION CO2 CAPTURE

82 83

Oxy-combustion consists of burning fossil fuels in a mixture of pure oxygen and re-circulated flue

gas, resulting in CO2-rich flue gas (free of nitrogen, contrary to conventional air-fired power plants).

The pure oxygen is supplied by a cryogenic air separation unit (ASU).

Oxy-combustionTarget (estimated future commercial) Status (today’s offering)

Boiler Type Two-pass, tower Two-pass

Fuel

• Bituminous, sub-bituminous• Lignite• Oil, gas• Biomass (part load)

• Bituminous, sub-bituminous• Biomass (part load)

Size Up to 1,350 MWe Up to 448 MWe

Steam Condition• Ultra-supercritical• Up to 605°C/623°C/300 bar

• Ultra-supercritical • Up to 605°C/623°C/279 bar

Gas Processing UnitParameters Target (estimated future commercial) Status (today’s offering)

Temperature (°C) 20 – 100 20 – 100

Pressure (bars) 1 1

Flow Rate (t/h) 1,400 Up to 875

C02 Vol (% dry basis) 70 – 95 70 – 95

H2O Vol (%) 2 – 25 2 – 25

N2 Vol (% dry basis) 2 – 5 2 – 5

O2 Vol (% dry basis) 20 – 50 20 – 50

C02 Capture Rate(%) 90 90

C02 Product Specification and Conditions

Temperature (°C) As Required As Required

Pressure (bars) As Required As Required

Flow Rate (t/h) Up to 600 Up to 276

C02 (mol-%) > 95 – >99 Depending on Need > 95 – >99 Depending on Need

H2O (mol-ppm) As Required As Required

Key Benefits • Reliable and robust process

• Adaptable to most boiler and fuel types with the potential for rapid scale up, even up to the 1,000 MWe range

• Operational flexibility options

• Available for retrofit to existing power plants

• Integrated GE approach, providing both technical and economical benefits

The oxy-combustion boiler has been under development for more than a decade, starting with research and the subsequent establishment of a laboratory pilot in the 1990s. GE has been at the forefront of oxy-combustion development, and we:

• developed the first oxy pilot plant at a site in Germany

• demonstrated the entire oxy-technology chain including a gas processing unit in the boiler simulation facility located in Windsor, Connecticut, USA.

GE is also developing the gas processing unit (GPU), which is designed to further treat and process the flue gas downstream of the oxy-boiler, delivering CO2 at the required specification. As part of the validation program, a mobile pilot unit was built for testing under multiple oxy configurations.

Oxy-combustion, a flexible technology for all types of fuel

ASUAirSeparationUnit

oxy-Boiler ESP/Bag FilterDust elimination

FGD Desulphurization

GPU Gas Processing Unit

CO2 Storage

FGC Flue Gas Condenser

Nitrogen

Coal Mill

Powering the World

Page 45: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

POST COMBUSTION CO2 CAPTURE Chilled Ammonia Process (CAP)

The chilled ammonia process (CAP) is a proprietary technology being developed by GE. Field validation

tests have successfully demonstrated more than 99.9 percent pure CO2 product quality at 90 percent

capture rates on combustion flue gas originating from oil, gas, and coal fuels. CAP features include:

• High CO2 product purity

• CO2 capture process tolerant to oxygen and flue gas impurities

• Stable reagent, no degradation or emission of trace contaminants

• Low-cost, globally available reagent

• Ability to use low ambient conditions to further reduce the energy consumption of the process

• Integrated approach from GE, providing both economic and technical benefits

84 85

NOTE: Regenerator pressure at 20 bara

STEAM POWER SYSTEMS PRODUCT CATALOG I CO2 Capture Solutions

Environmentally benign in terms of emissions, CAP is a chemical absorption process using an ammonium-based aqueous solvent. The flue gas is contacted with chemical solvent – forming ammonium bicarbonate, ammonium carbonate and ammonium carbamate. The chemical reactions are reversible, and raising the temperature and the pressure of the reaction products reverses the capture reactions, releasing CO2 and allowing the solvent to be regenerated and returned to the process.

CAP technology can be applied to various types of power plants such as coal, gas and biomass, as well as a vast range of industrial processes emitting CO2. The technology uses ammonia for the solvent, which is a globally available, low-cost commodity chemical with excellent thermal and chemical properties.

CAP

Parameters Target (estimated future commercial) Status (today’s offering)

Flue Gas Inlet Conditions  

Temperature (°C) 45 – 100 45 – 100

Pressure (bara) 1 1

Flow Rate (t/h) Up to 3,000 Up to 1,150

C02 Vol (% dry basis) 4 – 16 4 – 16

H2O Vol (%) 5 – 10 5 – 10

N2 Vol (% dry basis) 70 70

O2 Vol (% dry basis) 2 – 6 2 – 6

C02 Capture Rate (%) Up to 90 Up to 90

CO2 Product Specification and Conditions

Temperature (°C) As Required As Required

Pressure (bara) As Required As Required

Flow Rate (t/h) Up to 800 10 – 200

C02 (mol-%) Up to 99.9 Up to 99.9

H2O (mol-ppm) As Required As Required

CAP, a state-of-the-art CO2 capture technology

Flue Gas Cooling/conditioning

CO2 Absorption CO2 Regeneration

CO2 Storage

Powering the World

Page 46: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Amine-based carbon capture processes have been proven for decades in natural gas and syngas purification.

Our Advanced Amine Process (AAP) applied to flue gases was developed jointly with Dow Chemical Company.

Some key benefits of this process include:

• More energy efficient capture and compression of the CO2 product

• Designed for stringent emissions mitigation and control

• Less solvent degradation than Monoethanolamine (MEA), leading to lower chemical consumption

and lower production of effluents and waste

• Adaptable to new and installed base for both coal- and gas-fired plants

• Higher tolerance against oxygen and trace contaminants

86 87

STEAM POWER SYSTEMS PRODUCT CATALOG I CO2 Capture Solutions

AAP

Parameters Target (estimated future commercial) Status (today’s offering)

Flue Gas Inlet Conditions  

Temperature (°C) 30 – 100 30 – 100

Pressure (bara) 1 1

Flow Rate (t/h) Up to 4,000 Up to 1,150

C02 Vol (% dry basis) 3 – 15 4 – 15

H2O Vol (%) 5 – 30 5 – 30

N2 Vol (% dry basis) 70 – 90 70 – 90

O2 Vol (% dry basis) 3 – 10 3 – 10

C02 Capture Rate (%) Up to 90 Up to 90

CO2 Product Specification and Conditions

Temperature (°C) As Required As Required

Pressure (bara) As Required As Required

Flow Rate (t/h) Up to 800 12.5 – 230

C02 (mol-%) > 99.5 – 99.9 > 99.5 – 99.9

H2O (mol-ppm) As Required As Required

The flue gas is bound with the chemical solvent – Advanced Amine – which binds selectively to the flue gas CO2. Raising the temperature reverses the capture reaction, releasing CO2 and allowing the solvent to be recycled.

The technology has been demonstrated successfully in the field at 90 percent capture rates. Based on the low physical solubility of N2 and O2 in aqueous amines, CO2 product purity is greater than 99.5 percent after CO2 compression and dehydration. The highly selective reaction with CO2 is an important advantage of any alkaline scrubbing process and distinguishes this process from the results obtained from physical solvents, membranes or adsorbents.

Flue Gas Cooling/conditioning

CO2 AbsorptionCO2 Regeneration

CO2 Storage

Optimization of a well-known process for a new application

Powering the World

POST COMBUSTION CO2 CAPTURE Advanced Amine Process (AAP)

Page 47: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Our Customers Determine Our Success.

POWER

TRANSPORTATION

ENERGY MANAGEMENT

AVIATION

OIL & GAS

HEALTHCARE

APPLIANCES & LIGHTING

Combustion science & services, installed

base

Electrification, controls & power conversion

technology

Services & technology — a first-mover in growth regions

RENEWABLE ENERGY

Clean and productive Wind and Hydro

power generation services

GLOBALRESEARCH

GLOBALGROWTH

ORGANIZATION

DIGITALCULTURE &

SIMPLIFICATION

Advanced material, manufacturing &

engineering productivity

Engine technology & localization in growth regions

LED — a gateway to energy efficiency

Diagnostics technology — a first-mover & anchor

in growth regions

The GE StoreDRIVING COMPETITIVE ADVANTAGE ACROSS OUR BUSINESSES

We drive enterprise advantages that benefit the entire company through what we call the “GE Store.” It means that every business in GE can share and access the same technology, structure and intellect. The value of the GE Store is captured by faster growth at higher margins; it makes the totality of GE more competitive than the parts. No other company has the ability to transfer intellect and technology the way GE can through the Store.

Page 48: GE Power Powering the World · Coal power is the most mature and the most common power generation technology in the world. ... To optimize the thermodynamic cycle, we have enhanced

Steam Power Systems: Powering the World

[email protected]

* Trademark of General Electric Company.

GEA31876 (08/2015)